JPH05254059A - Production of decorative plywood - Google Patents

Abstract

PURPOSE:To produce stable decorative plywood of high quality generating no dimensional shift between plywood and a surface decorative sheet part, having the pattern of the decorative sheet part certainly corresponding to its surface uneven pattern and generating no warp. CONSTITUTION:Plywood is preliminarily heat-treated to be lowered in its moisture content and a thermoplastic decorative sheet 3 is laminated to the plywood 2 through an adhesive. Thereafter, a mold having the uneven surface corresponding to the pattern of the decorative sheet 3 is pressed to the decorative sheet 3 and, in this state, high frequency welder processing is applied to the decorative sheet not only to apply an uneven pattern to the surface of the decorative sheet but also to integrate the plywood 2 and the decorative sheet 3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a plywood for makeup, which is mainly used as a floor material or a wall material for interiors of general houses and shops.

[0002]

2. Description of the Related Art In the case of this type of decorative plywood, conventionally, a surface decorative sheet portion to be laminated on the plywood is manufactured in advance, and the surface decorative sheet portion is attached to the plywood with an adhesive. Manufacturing was the common method. The surface decorative sheet portion is a wood grain pattern, an abstract pattern,
A transparent sheet having an uneven surface corresponding to the pattern is laminated on a decorative sheet having a concrete pattern printed thereon.

Further, after a decorative sheet on which a wood grain pattern or the like is printed is superposed on the plywood, a transparent sheet is superposed on the decorative sheet and press working (heating and pressure curing),
There is a method of manufacturing a plywood for makeup by applying a concavo-convex pattern to the transparent sheet and fusing and integrating both sheets.

In addition, as a method for producing vinyl chloride tiles related to the above-mentioned decorative plywood, Japanese Patent Publication No.
There is a method described in Japanese Patent No. 75222. In this manufacturing method, a decorative sheet having a wood grain pattern or the like printed thereon is laid on a vinyl chloride resin substrate, a transparent sheet is laid on the decorative sheet, and a silicon resin embossed plate is further placed on the transparent sheet. After overlapping, a high-frequency voltage is applied to fuse and integrate the base material, the decorative sheet, and the transparent sheet, and the embossing plate is removed.

[0005]

However, the above-mentioned conventional manufacturing methods have the following problems.

Conventional General Manufacturing Method (First Described)
Then, when the surface decorative sheet portion is laminated on the plywood, the surface decorative sheet portion often expands and contracts to cause a dimensional error with the plywood. For this reason, when a large number of makeup plywoods are combined, for example, when constructing as an interior flooring material, the patterns and the like of adjacent makeup plywoods do not match.

In the manufacturing method using press working, the working time is very long and the production efficiency is poor, so that the manufacturing cost becomes high. Further, the decorative sheet on the surface is discolored or the plywood is warped under the influence of heat for a long time during the press working.

Since the base material is a vinyl chloride resin, the manufacturing method described in the above publication cannot be directly applied to the manufacturing method of the plywood which is the object of the present invention. That is, plywood is used as the base material, and a decorative sheet or a transparent sheet is superposed on the plywood,
When a silicone resin embossing plate is further stacked on it and subjected to high-frequency welding, the moisture contained in the plywood is vaporized and gasified, and the gas breaks the decorative sheet, creates holes, Gas accumulates between the sheet and the plywood, causing swelling (also known as buku), which deteriorates the appearance. Further, during the high-frequency welding process, the embossing mold made of silicon resin may expand, and the pattern of the decorative sheet and the uneven pattern that should originally correspond to the pattern may be displaced. Further, the high-frequency welding process may cause warp in the plywood.

The present invention has been made in view of the above-mentioned points, and there is no dimensional deviation between the plywood and the surface decorative sheet portion, and the pattern of the decorative sheet portion and the uneven pattern of the surface surely correspond to each other. It is an object of the present invention to provide a high-quality and stable production method of a plywood for makeup, which is free from warpage.

[0010]

In order to achieve the above-mentioned object, the method for producing a decorative plywood of the present invention comprises: a) reducing the water content of the plywood in advance, and applying thermoplasticity to the plywood via an adhesive. After the above-mentioned decorative sheet is stuck together, b) the decorative sheet is subjected to high-frequency welding processing or ultrasonic welding processing in a state where a mold having an uneven surface corresponding to the pattern is pressed against the decorative sheet. The plywood and the decorative sheet are integrated with each other while providing an uneven pattern on the surface of the plywood.

As described in claim 2, it is preferable that the water content of the plywood is 3% or less.

Further, as described in claim 3, high frequency welding may be performed by applying a high frequency voltage to the plywood laminated with the decorative sheet by using the mold for one electrode.

[0013]

According to the manufacturing method of the present invention having the above structure,
Welding is performed with a thermoplastic decorative sheet adhered to the plywood with an adhesive, so an uneven pattern with high dimensional accuracy that is symmetrical to the uneven surface of the mold is applied to the surface of the decorative sheet. Also, the decorative sheet does not expand or contract after processing, and the dimensional accuracy is stable. Moreover, since the water content of the plywood is lowered (adjusted) in advance, evaporation of water in the plywood hardly occurs during the welding process, so that it is difficult for the decorative sheet to be bubbled or the plywood to be warped.

Particularly, according to the manufacturing method of claim 2,
Since the water in the plywood does not evaporate during the welding process, a decorative sheet with an excellent appearance can be reliably obtained.

According to the manufacturing method of the third aspect, since the mold itself serves as an electrode, the structure is simplified and the welding process is facilitated.

[0016]

EXAMPLES The method for producing a plywood for makeup of the present invention will be described below with reference to its examples.

FIG. 1 is an enlarged vertical sectional view showing a part of a decorative plywood manufactured by the manufacturing method of the present invention, and FIG. 2 shows a mold which also serves as an electrode for high-frequency welding, and FIG.
Is a plan view, and FIG. 6B is a sectional view taken along the line AA ′ of FIG.

As shown in FIG. 1, a plywood 1 for makeup is laminated on a plywood 2 having a thickness of 9.0 mm as a substrate, and a decorative sheet 3 made of vinyl chloride resin having a thickness of about 1.0 mm is laminated and integrated. Composed of structure. The decorative sheet 3 includes a backer sheet 3a as a base material, a print sheet 3b having a pattern 3c such as a marble pattern or a wood grain pattern printed on the surface, and a matte surface 3e corresponding to the pattern 3c and the periphery of the matte surface 3e. It has a three-layer structure in which a transparent sheet 3d having a glossy surface 3f provided in a frame shape with a constant width formed on the surface is laminated in order from the bottom. The matte surface 3e is formed by forming the surface of the transparent sheet 3d into an uneven surface, and the glossy surface 3f is formed by forming the surface of the transparent sheet 3d into a mirror surface. An inverted trapezoidal or V-shaped groove 3g is formed at the boundary between the matte surface 3e and the glossy surface 3f.

On the other hand, the transparent sheet 3d of the decorative plywood 1
The mold 10 for forming the matte surface (uneven surface) 3e and the glossy surface (mirror surface) 3f on the surface of the mold has a constant width (for example, 61 mm) and a constant length, as shown in FIG. 2 (a). (For example, 386 mm / 486 mm) rectangular uneven surfaces (also referred to as mats) 10 a are provided at eight places, and the uneven surfaces 10 a
A mirror surface (also referred to as gloss) 10b having a constant width (for example, 12 mm and 7 mm) is provided around a. Also, the uneven surface 1
At the boundary between 0a and the mirror surface 10b and around the mirror surface 10b,
As shown in FIG. 2B, a protrusion 10c having a trapezoidal cross section with a constant width (for example, 2 mm) is formed. Further, the mold 10 is entirely formed of a metal material such as zinc, and also serves as one (upper) electrode during the high frequency welding process.

The makeup plywood 1 is manufactured by the process described below, and the surface shape of the makeup plywood 1 corresponds to the shape of the mold 10. The makeup plywood 1 is separated from the mold 10 by a partition line 10d. 2 pieces (plywood) are cut along (FIG. 2 (a)), only 4 pieces are cut only in the longitudinal direction, or 4 pieces of plywood are left without being cut.

Decorative plywood 1 having the above structure (FIG. 1)
Is manufactured by the following steps.

For example, a marble pattern is printed on the calender-formed print base sheet 3b, and the calender-formed transparent sheet 3d is laminated on the printed print base sheet 3b to be laminated integrally, and further calender-formed. Backer sheet 3a as a base material
The decorative sheet 3 is manufactured by laminating the print base sheet 3b on the top and laminating it integrally with an adhesive.

On the waterproof plywood 2, a backer sheet 3a of a decorative sheet 3 having a marble pattern or the like printed on its surface is attached by an adhesive and laminated integrally. In addition, plywood 2
Is, for example, placed in an oven and dried (for example, at an oven temperature of 80 ° C. for 1 day), and the water content is adjusted in advance (for example, the water content which is usually about 6 to 15% is reduced to or near 0%). Keep it.

The plywood 2 is set on the lower electrode surface of the high frequency welder, and the die 10 is pressed with a constant pressure on the uppermost transparent sheet 3d of the set plywood 2 with the die surface facing down. Then, in this state, a high frequency voltage is applied to carry out a welder process.

After the welding process is performed for a fixed time (usually 10 to 12 seconds), the temperature is cooled to room temperature and the mold 10 is removed from the transparent sheet 3d, and the manufacturing process of the decorative plywood 1 is completed. Finally, as described above, 8
Separated into plywood.

When the finished dimensions of the plywood 2 and the decorative sheet 3 on the plywood 1 for makeup manufactured as described above were examined, the dimensional difference was 0 mm and there was no deviation. In addition, the decorative sheet 3 did not have a defect in appearance such as blurring, and the plywood 2 did not warp.

On the other hand, in order to compare the manufacturing method of the present invention with the conventional manufacturing method, the decorative sheet 3 manufactured on the basis of the above, in other words, in a state where the decorative sheet 3 is not attached to the plywood 2, High-frequency welding is performed using the mold 10 and the matte surface 3e is formed on the uppermost transparent sheet 3d.
After forming the above, the decorative sheet 3 was attached by an adhesive to the plywood 2 which was previously dried and adjusted to have a water content, and integrated to manufacture a decorative plywood (length 250 mm, width 200 mm). In the case of this plywood for makeup, as shown in the comparison table described later, the makeup sheet 3 has a length direction of 0.51 to 3.07 mm,
There was expansion and contraction of about 0.5 to 1.5 mm in the width direction, causing a deviation from the mold dimension.

FIG. 3 is an enlarged vertical sectional view showing a part of a decorative plywood according to another embodiment manufactured by the manufacturing method of the present invention.

The makeup plywood 1'shown in the figure differs from the above-mentioned makeup plywood 1 (FIG. 1) in that the base material of the makeup sheet 3'is 30 g / in addition to the backer sheet 3a.
This is the point that the nonwoven fabric sheet 3h of m ² of glass fiber was used. That is, the backer sheet 3a is integrally stuck on the non-woven fabric sheet 3h of glass fiber with an adhesive and laminated integrally as a base material, and the plywood 2 is stuck with the adhesive. However, other configurations and manufacturing methods are the same as in the case of the above-mentioned decorative plywood 1, and therefore detailed description thereof will be omitted. As for the production results of the makeup plywood 1 ', as is clear from the following comparison table comparing the above-mentioned makeup plywood 1 with the conventional production method, the makeup plywood 1.1' according to the production method of the present invention is It was excellent.

(1) Cosmetic plywood 1 according to the manufacturing method of the present invention
Comparison between 1'and plywood for makeup by the conventional manufacturing method described in A above:

[Table 1] Finishing dimensions mm Shrinkage after lamination with plywood mm Overall evaluation Makeup plywood 1 Length ± 0 Length ± 0 ○ (without glass fiber nonwoven fabric) Width ± 0 Width ± 0 Makeup plywood 1'Length ± 0 Length ± 0 ○ (with glass fiber non-woven fabric) Width ± 0 Width ± 0 Decorative sheet 3 Single length -3.07 Length ± 0 x (without glass fiber non-woven) Width ± 1.5 Width ± 0 Decorative sheet 3 'Single unit length +0.51 length ± 0 △ (with glass fiber non-woven fabric) width ± 0.5 width ± 0 plywood 2 dimensions; length 250 mm, width 200 mm decorative sheet 3 dimensions; length 250 mm, width 200 mm plywood Material of 2; Wooden Material of decorative sheet; Expansion and contraction dimension after lamination with vinyl chloride resin plywood was measured after a lapse of 6 hours at a temperature of 80 ° C. Moreover, also in the conventional example (lower two stages of Table 1), the plywood 2 was bonded after heat treatment.

(Comparison result) In the conventional manufacturing method, the plywood 2
A dimensional deviation occurred between the decorative sheet 3 and the decorative sheet 3, but the manufacturing method of the present invention did not cause a dimensional deviation between the plywood 2 and the decorative sheet 3. Even in the conventional manufacturing method, after the decorative sheet 3 was attached to the plywood 2, the decorative sheet 3 did not expand or contract.

(2) Comparison between the case where the water content of the plywood 2 is adjusted and the case where it is not adjusted: In the process of producing a cosmetic plywood by the above-described production method of the present invention, the upper three stages of Table 2 below are oven dried. Then, the plywood of which the water content was adjusted was used, and the lower two stages used the plywood in a naturally dried state (water content was not adjusted).

[0033]

[Table 2] Drying process Moisture content Appearance Defects Comprehensive evaluation of warpage of plywood Oven 0% None None ○ 2% after drying None None ○ Lamination on plywood 4% A little Yes No △ Natural drying 6% Yes Yes × On plywood Laminated with 10% Yes Yes Oven drying treatment was performed at an oven temperature of 80 ° C. for 1 day.

The above water content was determined by a water content test based on JAS "Standards for Vinyl Chloride Decorative Plywood".

The following thermosetting adhesives A and B were used to bond the decorative sheet 3 and the plywood, but there was no particular difference.

Adhesive A: a mixture of CVC33R (urethane modified vinyl resin) + CVC curing agent (water dispersion of ethylene urea derivative) manufactured by Konishi Co., Ltd. (mixing ratio 100: 5) Adhesive B: manufactured by Konishi Co., Ltd. CVC36F (urethane modified vinyl resin) + CVC curing agent (water dispersion of ethylene urea derivative) mixture (mixing ratio 100: 5) (comparison result) In the production method of the present invention using plywood after oven drying, When the ratio was 0 and 2%, there were no external defects and no warpage occurred on the plywood, but the water content was 4%.
Then, the appearance defect occurred. Therefore, it was found that it is necessary to reduce the water content of the plywood to about 3%. On the other hand, when the naturally dried plywood was used, appearance defects and warpage of the plywood occurred. By the way, in the above-mentioned embodiment, the high frequency welding process is used, but the ultrasonic welding process can also be used.

[0037]

As is clear from the above description,
The manufacturing method of the plywood for makeup of the present invention has the following effects.

(1) Since the uneven surface or the like is molded by the welder processing with the decorative sheet attached on the plywood, the uneven surface or the like corresponding to the mold shape of the mold can be formed on the surface of the decorative sheet. Since the sheet does not expand and contract, there is no dimensional deviation from the plywood. Therefore, when the makeup plywood according to the production method of the present invention is used as, for example, a flooring material, even if a large number of makeup plywoods are combined, the patterns and the like of adjacent makeup plywoods match or are regularly arranged. , It is possible to construct a floor surface that is excellent in design and has a good finish.

(2) Since the water content of the plywood is lowered in advance, appearance defects such as blistering on the cosmetic sheet are less likely to occur, and warp of the plywood is less likely to occur, so that the cosmetic sheet is of high quality and stable. Plywood can be manufactured.

(3) In the manufacturing method according to the second aspect, a cosmetic plywood having a high quality and a stable quality is ensured without causing a defect in appearance such as swelling on the cosmetic sheet and causing no warp of the plywood. Can be manufactured.

(4) In the manufacturing method according to claim 3, since the mold itself serves as an electrode, the structure of the apparatus is simplified and the welding process is facilitated.

[Brief description of drawings]

FIG. 1 is an enlarged vertical sectional view showing a part of a plywood for cosmetics manufactured by a manufacturing method of the present invention, which is omitted.

2A and 2B show a mold that also serves as an electrode for high-frequency welding, FIG. 2A is a plan view, and FIG. 2B is A- in FIG. 2A.
It is an A'line sectional view.

FIG. 3 is an enlarged vertical cross-sectional view showing a part of a decorative plywood according to another embodiment manufactured by the manufacturing method of the present invention, with a part omitted.

[Explanation of symbols]

 1.1 'Makeup plywood 2 Plywood 3.3' Makeup sheet 3a Backer sheet 3d Transparent sheet 3e Matte surface 3f Glossy surface 3g Groove 10 Mold

Claims (3)

[Claims] 1. A metal having a water content of plywood reduced in advance, a thermoplastic decorative sheet attached to the plywood via an adhesive, and then a metal having an uneven surface corresponding to the pattern on the decorative sheet. A decorative plywood characterized by forming a concavo-convex pattern on the surface of the decorative sheet by performing high-frequency welder processing or ultrasonic welder processing while pressing the mold, and integrating the plywood and the decorative sheet. Manufacturing method. 2. The method of manufacturing a plywood for makeup according to claim 1, wherein the water content of the plywood is 3% or less. 3. The method for manufacturing a decorative plywood according to claim 1, wherein a high frequency voltage is applied to the plywood laminated with the decorative sheet by using the mold for one electrode and a high frequency welding process is performed.